Process for preparing long chain alkyl phenols

ABSTRACT

Long chain alkyl phenols are prepared by alkylating an alkylatable phenolic compound with a long chain alkylating agent under alkylation reaction conditions in the presence of catalyst comprising a synthetic porous crystalline material characterized by an X-ray diffraction pattern including interplanar d-spacings at 12.36±0.4, 11.03±0.2, 8.83±0.14, 6.18±0.12, 6.00±0.10, 4.06±0.07; 3.91±0.07 and 3.42±0.06 Angstroms.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent application Ser. No. 254,524, filed Oct. 6, 1988, which is a continuation-in-part of U.S. patent application Ser. No. 098,176, filed Sept. 18, 1987, abandoned which is a continuation-in-part of U.S. patent application Ser. No. 890,268, filed Jul. 29, 1986, abandoned.

BACKGROUND OF THE INVENTION

This invention relates to a process for preparing long chain alkyl phenols by alkylating an aromatic compound with a relatively long chain alkylating agent employing a synthetic porous crystalline material, or zeolite, as alkylation catalyst.

Zeolite materials, both natural and synthetic, have been demonstrated in the past to have catalytic properties for various types of hydrocarbon conversion. Certain zeolite materials are ordered, porous crystalline aluminosilicates having a definite crystalline structure as determined by X-ray diffraction, within which there are a large number of smaller cavities which may be interconnected by a number of still smaller channels or pores. These cavities and pores are uniform in size within a specific zeolitic material. Since the dimensions of these pores are such as to accept for adsorption molecules of certain dimensions while rejecting those of larger dimensions, these materials have come to be known as "molecular sieves" and are utilized in a variety of ways to take advantage of these properties. Such molecular sieves, both natural and synthetic, include a wide variety of positive ion-containig crystalline silicates. These silicates can be described as a rigid three-dimensional framework of SiO₄ and Periodic Table Group IIIA element oxide, e.g., AlO₄, in which the tetrahedra are cross-linked by the sharing of oxygen atoms whereby the ratio of the total Group IIIA element, e.g., aluminum, and silicon atoms to oxygen atoms is 1:2. The electrovalence of the tetrahedra containing the Group IIIA element, e.g., aluminum, is balanced by the inclusion in the crystal of a cation, e.g., an alkali metal or an alkaline earth metal cation. This can be expressed wherein the ratio of the Group IIA element, e.g., aluminum, to the number of various cations, such as Ca/2, Sr/2, Na, K or Li, is equal to unity. One type of cation may be exchanged either entirely or partially with another type of cation utilizing ion exchange techniques in a conventional manner. By means of such cation exchange, it has been possible to vary the properties of a given silicate by suitable selection of the cation. The spaces between the tetrahedra are occupied by molecules of water prior to dehydration.

Prior art techniques have resulted in the formation of a great variety of synthetic zeolites. Many of these zeolites have come to be designated by letter or other convenient symbols, as illustrated by zeolite Z (U.S. Pat. No. 2,882,243); zeolite X (U.S. Pat. No. 2,882,244); zeolite Y (U.S. Pat. No. 3,130,007); zeolite ZK-5 (U.S. Pat. No. 3,247,195); zeolite ZK-4 (U.S. Pat. No. 3,314,752), zeolite ZSM-5 (U.S. Pat. No. 3,702,886); zeolite ZSM-11 (U.S. Pat. No. 3,709,979); zeolite ZSM-12 (U.S. Pat. No. 3,832,449); zeolite ZSM-20 (U.S. Pat. No. 3,972,983); zeolite ZSM-35 (U.S. Pat. No. 4,016,245); and zeolite ZSM-23 (U.S. Pat. No. 4,076,842), merely to name a few.

The SiO₂ /Al₂ O₃ ratio of a given zeolite is often variable. For example, zeolite X can be synthesized with SiO₂ /Al₂ O₃ ratios of from 2 to 3; zeolite Y, from 3 to about 6. In some zeolites, the upper limit of the SiO₂ /Al₂ O₃ ratio is unbounded. ZSM-5 is one such example wherein the SiO₂ /Al₂ O₃ ratio is at least 5 and up to the limits of present analytical measurement techniques. U.S. Pat. No. 3,941,871 (RE. 29,948) discloses a porous crystalline silicate made from a reaction mixture containing no deliberately added alumina in the recipe and exhibiting the X-ray diffraction pattern characteristic of ZSM-5. U.S. Pat. Nos. 4,061,724; 4,073,865 and 4,104,294 describe crystalline silicates of varying alumina and metal content.

Several long chain alkyphenols are known useful items of commerce. p-Nonylphenol, for instance, which is used primarily in the manufacture of synthetic detergents, is currently produced in quantities of about 100 million pounds a year. Production of these compounds by conventional methods, for example, by the alkylation of phenol in the presence of conventional alkylation catalysts is, however, somewhat problematic in that the reaction yields a broad spectrum of products. Isolation or enrichment of specific positional isomers is both difficult and expensive.

Traditionally, alkylation reactions are generally carried out at atmospheric pressure with the reactants in the liquid phase utilizing catalyst such as sulfuric acid, boron trifluoride, aluminum chloride or strongly acidic ion exchange resins. Some zeolites, specifically REX and HY, have been reported in the scientific literature as catalyzing the reaction of 1-decyl alcohol with phenol at atmospheric pressure and 200° C. The product of that reaction was predominantly an ortho/para mixture of decyphenols with side chain attachment largely at the second and third carbon atoms of the alkyl group.

U.S. Pat. No. 4,283,573 describes a process for producing relatively long chain alkylphenols by alkylation of phenol with a long chain alkylating agent possessing one or more available alkyl groups of at least 5 carbon atoms in length employing as catalyst a zeolite such as cancrinite, gmelinite, mordenite, offretite or ZSM-12.

SUMMARY OF THE INVENTION

In accordance with the present invention, a process for the production of relatively long chain alkyl-substituted phenolic compounds is provided which comprises contacting at least one alkylatable phenolic compound with at least one alkylating agent possessing an alkylating aliphatic group having at least six carbon atoms under alkylation reaction conditions and in the presence of an alkylation catalyst to provide an alkylated phenolic compound possessing at least one alkyl group derived from said alkylating agent, said catalyst comprising a synthetic porous crystalline material characterized by an X-ray diffraction pattern including interplanar d-spacing at 12.36±0.4, 11.03±0.2, 8.83±0.14, 6.18±0.12, 6.00±0.10, 4.06±0.07, 3.91±0.07 and 3.42 ±0.06 Angstroms.

DESCRIPTION OF SPECIFIC EMBODIMENTS

The entire contents of applications Ser. Nos. 254,524; 98,176; and 890,268 are incorporated herein by reference.

The invention contemplates the reaction of alkylatable phenolic compounds with alkylating agents possessing a relatively long chain alkylating group, i.e., of at least about six carbon atoms. The preferred alkylatable phenolic compound is phenol but other phenolic reactants can be utilized to yield a variety of alkylation products. Non-limiting examples of phenolic compounds which can be used as feed herein include methhylphenols (cresols); dimethylphenols (xylenols); ethyl, propyl and butylphenols; halophenols (e.g., chloro and bromo); alkyhalophenols; alkoxyphenols; dihydroxybenzenes (e.g., hydroquinone catechol, resorcinol); hydroxylated fused ring systems, e.g., naphthols, anthranols and phenanthranols, and so forth.

The alkylating agents which are useful in the process of this invention generally include any aliphatic or aromatic organic compound having one or more available alkylating aliphatic groups capable of reaction with the alkylatable phenolic compound. The alkylatable group itself should have at least 6 carbon atoms, preferably at least about 8, and still more preferably at least about 12 carbon atoms.

Examples of suitable alkylating agents are olefins such as hexenes, heptenes, octenes, nonenes, decenes, undecenes, dodecenes and the like; alcohols (inclusive of monoalcohols, dialcohols, trialcohols, etc.) such as hexanols, heptanols, octanols, nonanols, decanols, undecanols and dodecanols; and alkyl halides such as hexyl chlorides, octyl chlorides, dodecyl chlorides; and, higher homologs of the foregoing. Branched alkylating agents, especially oligomerized olefins such as the trimers, tetramers, pentamers, etc., of light olefins such as ethylene, propylene, the butylenes, etc., are also useful herein.

In its calcined form, the synthetic porous crystalline material component employed in the catalyst composition used in the process of this invention is characterized by an X-ray diffraction pattern including the following lines:

                  TABLE A                                                          ______________________________________                                         Interplanar d-Spacing (A)                                                                     Relative Intensity, I/I.sub.o × 100                       ______________________________________                                         12.36 ± 0.4 M-VS                                                            11.03 ± 0.2 M-S                                                             8.83 ± 0.14 M-VS                                                            6.18 ± 0.12 M-VS                                                            6.00 ± 0.10 W-M                                                             4.06 ± 0.07 W-S                                                             3.91 ± 0.07 M-VS                                                            3.42 ± 0.06 VS                                                              ______________________________________                                    

Alternativley, it may be characterized by an X-ray diffraction pattern in its calcined form including the following lines:

                  TABLE B                                                          ______________________________________                                         Interplanar d-Spacing (A)                                                                     Relative Intensity, I/I.sub.o × 100                       ______________________________________                                         30.0 ± 2.2  W-M                                                             22.1 ± 1.3  W                                                               12.36 ± 0.4 M-VS                                                            11.03 ± 0.2 M-S                                                             8.83 ± 0.14 M-VS                                                            6.18 ± 0.12 M-VS                                                            6.00 ± 0.10 W-M                                                             4.06 ± 0.07 W-S                                                             3.91 ± 0.07 M-VS                                                            3.42 ± 0.06 VS                                                              ______________________________________                                    

More specifically, the calcined form may be characterized by an X-ray diffraction pattern including the following lines:

                  TABLE C                                                          ______________________________________                                         Interplanar d-Spacing (A)                                                                     Relative Intensity, I/I.sub.o × 100                       ______________________________________                                         12.36 ± 0.4 M-VS                                                            11.03 ± 0.2 M-S                                                             8.83 ± 0.14 M-VS                                                            6.86 ± 0.14 W-M                                                             6.18 ± 0.12 M-VS                                                            6.00 ± 0.10 W-M                                                             5.54 ± 0.10 W-M                                                             4.92 ± 0.09 W                                                               4.64 ± 0.08 W                                                               4.41 ± 0.08 W-M                                                             4.25 ± 0.08 W                                                               4.10 ± 0.07 W-S                                                             4.06 ± 0.07 W-S                                                             3.91 ± 0.07 M-VS                                                            3.75 ± 0.06 W-M                                                             3.56 ± 0.06 W-M                                                             3.42 ± 0.06 VS                                                              3.30 ± 0.05 W-M                                                             3.20 ± 0.05 W-M                                                             3.14 ± 0.05 W-M                                                             3.07 ± 0.05 W                                                               2.99 ± 0.05 W                                                               2.82 ± 0.05 W                                                               2.78 ± 0.05 W                                                               2.68 ± 0.05 W                                                               2.59 ± 0.05 W                                                               ______________________________________                                    

Most specifically, it may be characterized in its calcined form by an X-ray diffraction pattern including the following lines:

                  TABLE D                                                          ______________________________________                                         Interplanar d-Spacing (A)                                                                     Relative Intensity, I/I.sub.o × 100                       ______________________________________                                         30.0 ± 2.2  W-M                                                             22.1 ± 1.3  W                                                               12.36 ± 0.4 M-VS                                                            11.03 ± 0.2 M-S                                                             8.83 ± 0.14 M-VS                                                            6.86 ± 0.14 W-M                                                             6.18 ± 0.12 M-VS                                                            6.00 ± 0.10 W-M                                                             5.54 ± 0.10 W-M                                                             4.92 ± 0.09 W                                                               4.64 ± 0.08 W                                                               4.41 ± 0.08 W-M                                                             4.25 ± 0.08 W                                                               4.10 ± 0.07 W-S                                                             4.06 ± 0.07 W-S                                                             3.91 ± 0.07 M-VS                                                            3.75 ± 0.06 W-M                                                             3.56 ± 0.06 W-M                                                             3.42 ± 0.06 VS                                                              3.30 ± 0.05 W-M                                                             3.20 ± 0.05 W-M                                                             3.14 ± 0.05 W-M                                                             3.07 ± 0.05 W                                                               2.99 ± 0.05 W                                                               2.82 ± 0.05 W                                                               2.78 ± 0.05 W                                                               2.68 ± 0.05 W                                                               2.59 ± 0.05 W                                                               ______________________________________                                    

These values were determined by standard techniques. The radiation was the K-alpha doublet of copper and a diffractometer equiped with a scintillation counter and an associated computer was used. The peak heights, I, and the positions as a function of 2 theta, where theta is the Bragg angle, were determined using algorithms on the computer associated with the diffractometer. From these, the relative intensites, 100 I/I_(o), where I_(o) is the intensity of the strongest line or peak, and d (obs.) the interplanar spacing in Angstrom Units (A), corresponding to the recorded lines, were determined. In Tables A-D, the relative intensities are given in terms of the symbols W=weak, M=medium, S=strong, VS=very strong. In terms of intensities, these may be generally designated as follows:

    W = 0-20

    M = 20-40

    S = 40-60

    VS = 60-100

It should be understood that these X-ray diffraction patterns are characteristic of all species of the zeolite. The sodium form as well as other cationic forms reveal substantially the same pattern with some minor shifts in interplanar spacing and variation in relative intensity. Other minor variations can occur depending on the ration of structural components, e.g. silicon to aluminum mole ratio of the particular sample, as well as its degree of thermal treatment.

Examples of such porous crystalline materials include the PSH-3 composition of U.S. Pat. No. 4,439,409, incorporated herein by reference, and MCM-22.

Zeolite MCM-22 has a composition involving the molar relationship:

    X.sub.2 O.sub.3 :(n)YO.sub.2,

wherein X is a trivalent element, such as aluminum, boron, iron and/or gallium, preferably aluminum, Y is a tetravalent element such as silicon and/or germanium, preferably silicon, and n is at least about 10, usually from about 10 to about 150, more usually from about 10 to about 60, and even more usually from about 20 to about 40. In the as-synthesized form, zeolite MCM-22 has a formula, on an anhydrous basis and in terms of moles oxides per n moles of YO₂, as follows:

    (0.005-0.1)Na.sub.2 O:(1-4)R:X.sub.2 O.sub.3 :nYo.sub.2

wherein R is an organic component. The Na and R components are associated with the zeolite as a result of their presence during crystallization, and are easily removed by post-crystallization methods hereinafter more particularly described.

Zeolite MCM-22 is thermally stable and exhibits a high surface area greater than about 400 m² /gm as measured by the BET (Bruenauer, Emmet and Teller) test and unusually large sorption capacity when compared to previously described crystal structures having similar X-ray diffraction patterns. As is evident from the above formula, MCM-22 is synthesized nearly free of Na cations and thus possesses acid catalysis activity as synthesized. It can, therefore, be used as a component of the alkylation catalyst composition herein without having to first undergo an exchange step. To the extent desired, however, the original sodium cations of the as-synthesized material can be replaced in accordance with techniques well known in the art, at least in part, by ion exchange with other cations. Preferred replacement cations include metal ions, hydrogen ions, hydrogen precursor, e.g., ammonium, ions and mixtures thereof. Particularly preferred cations are those which tailor the activity of the catalyst for preparing long chain alkylphenols. These include hydrogen, rare earth metals and metals of Groups IIA, IIIA, IVA, IB, IIB, IIIB, IVB and VIII of the Periodic Table of the Elements.

In its calcined form, zeolite MCM-22 appears to be made up of a single crystal phase with little or no detectable impurity crystal phases and has an X-ray diffraction pattern including the lines listed in above Tables A-D.

Prior to its use as alkylation catalyst, the zeolite should be subjected to thermal treatment to remove part or all of any organic constituent present therein.

The zeolite alkylation catalyst herein can also be used in intimate combination with a hydrogenating component such as tungsten, vanadium, molybdenum, rhenium, nickel, cobalt, chromium, manganese, or a noble metal such as platinum or palladium where a hydrogenation-dehydrogenation function is to be performed. Such component can be introduced in the catalyst composition by way of co-crystallization, exchanged into the composition to the extent a Group IIIA element, e.g., aluminum, is in the structure impregnated therein or intimately physically admixed therewith. Such component can be impregnated in, or on, the zeolite such as, for example, by, in the case of platinum, treating the zeolite with a solution containing a platinum metal-containing ion. Thus, suitable platinum compounds for this purpose include chloroplatinic acid, platinous chloride and various compounds containing the platinum amine complex.

The zeolite, especially in its metal, hydrogen and ammonium forms, can be beneficially converted to another form by thermal treatment. This thermal treatment is generally performed by heating one of these forms at a temperature of at least about 370° C. for at least 1 minute and generally not longer than 20 hours. While subatmospheric pressure can be employed for the thermal treatment, atmospheric pressure is preferred simply for reasons of convenience. The thermal treatment can be performed at a temperature of up to about 925° C.

Prior to its use in the alkylation process of this invention, the zeolite crystals should be dehydrated, at least partially. This can be done by heating the crystals to a temperature in the range of from about 200° C. to about 595° C. in an inert atmosphere, such as air, nitrogen, etc. and at atmospheric, subatmospheric or superatmospheric pressures for between about 30 minutes to about 48 hours. Dehydration can also be preformed at room temperature merely by placing the crystalline material in a vacuum, but a longer time is required to obtain a sufficient amount of dehydration.

Zeolite MCM-22 can be prepared from a reaction mixture containing sources of alkali or alkaline earth metal (M), e.g., sodium or potassium, cation, an oxide of trivalent element X, e.g., aluminum, an oxide of tetravalent element Y, e.g., silicon, an organic (R) directing agent, hereinafter more particularly described, and water, said reaction mixture having a composition, interms of moles ratios of oxides, within the following ranges:

    ______________________________________                                         Reactants      Useful   Preferred                                              ______________________________________                                         YO.sub.2 /X.sub.2 O.sub.3                                                                      10-60   10-40                                                  H.sub.2 O/YO.sub.2                                                                              5-100  10-50                                                  OH.sup.- /YO.sub.2                                                                            0.01-1.0 0.1-0.5                                                M/YO.sub.2     0.01-2.0 0.1-1.0                                                R/YO.sub.2     0.05-1.0 0.1-0.5                                                ______________________________________                                    

In a preferred method of synthesizing zeolite MCM-22, the YO₂ reactant contains a substantial amount of solid YO₂, e.g., at least about 30 wt.% solid YO₂. Where YO₂ is silica, the use of a silica source containing at least about 30 wt.% solid silica, e.g., Ultrasil (a precipitated, spray dried silica containing about 90 wt.% silica) or HiSil (a precipitated hydrated SiO₂ containing about 87 wt.% silica, about 6 wt.% free H₂ O and about 4.5 wt.% bound H₂ O of hydration and having a particle size of about 0.02 micron) favors crystal formation from the above mixture. If another source of oxide of silicon e.g., Q-Brand (a sodium silicate comprised of about 28.8 wt.% of SiO₂, 8.9 wt.% Na₂ O and 62.3 wt.% H₂ O) is used, crystallization may yield little if any MCM-22 crystalline material and impurity phases of other crystal structures, e.g., ZSM-12, may be produced. Preferably, therefore, the YO₂, e.g., silica, source contains at least about 30 wt.% solid YO₂, e.g., silica, and more preferably at least about 40 wt.% solid YO₂, e.g., silica.

Crystallization of the MCM-22 crystalline material can be carried out at either static or stirred conditions in a suitable reactor vessel such as, e.g., polypropylene jars or teflon-lined or stainless steel autoclaves. The total useful range of temperatures for crystallization is from about 80° C. to about 225° C. for a time sufficient for crystallization to occur at the temperature used. e.g., from about 25 hours to about 60 days. Thereafter, the crystals are separated from the liquid and recovered.

The organic directing agent for use in synthesizing zeolite MCM-22 from the above reaction mixture is hexamethyleneimine.

It should be realized that the reaction mixture components can be supplied by more than one source. The reaction mixture can be prepared either batchwise or continuously. Crystal size and crystallization time of the MCM-22 crystalline material vary with the nature of the reaction mixture employed and the crystallization conditions.

In all cases, synthesis of the MCM-22 crystals is facilitated by the presence of at least about 0.01 percent, preferably about 0.10 percent and still more preferably about 1 percent, seed crystals (based on total weight) of the crystalline product.

The zeolite crystals can be shaped into a wide variety of particle sizes. Generally speaking, the particles can be in the form of a powder, a granule, or a molded product such as an extrudate having a particle size sufficient to pass through a 2 mesh (Tyler) screen and be retained on a 400 mesh (Tyler) screen. In cases where the catalyst is molded, such as by extrusion, the crystals can be extruded before drying or partially dried and then extruded.

It may be desired to incorporate the crystalline material with another material which is resistant to the temperatures and other conditions employed in the alkylation process of this invention. Such materials include active and inactive materials and synthetic or naturally occurring zeolite as well as inorganic materials such as clays, silica and/or metal oxides such as alumina. The latter may be either naturally occurring or in the form of gelatinous precipitates or gels including mixtures of silica and metal oxides. Use of a material in conjunction with the zeolite, i.e., combined therewith or present during its synthesis, which itself is catalytically active may change the conversion and/or selectivity of the catalyst. Inactive materials suitably serve as diluents to control the amount of conversion so that alkylation products can be obtained economically and orderly without employing other means for controlling the rate of reaction. These materials may be incorporated into naturally occurring clays, e.g., bentonite and kaolin, to improve the crush strength of the catalyst under commercial alkylation operating conditions. Said materials, i.e., clays, oxides, etc., function as binders for the catalyst. It is desirable to provide a catalyst having good crush strength because in commercial use, it is desirable to prevent the catalyst from breaking down into powder-like materials. These clay binders have been employed normally only for the purpose of improving the crush strength of the catalyst.

Naturally occurring clays which can be composited with the crystals include the montmorillonite and kaolin family, which families include the subbentonites, and the kaolins commonly known as Dixie, McNamee, Georgia and Florida clays or others in which the main mineral constituent is halloysite, kaolinite, dickite, nacrite, or anauxite. Such clays can be used in the raw state as originally mined or initially subjected to calcination, acid treatment or chemical modification. Binders useful for compositing with zeolite also include inorganic oxides, notably alumina.

In addition to the foregoing materials, the zeolite crystals can be composited with a porous matrix material such as silica-alumina, silica-magnesia, silica-zirconia, silica-thoria, silica-beryllia, silica-titania as well as ternary compositions such as silica-alumina-thoria, silica-alumina-zirconia silica-alumina-magnesia and silica-magnesia-zirconia. It may also be advantageous to provide at least a part of the foregoing matrix materials in colloidal form so as to facilitate extrusion of the bound catalyst component(s).

The relative proportions of finely divided crystalline material and inorganic oxide matrix vary widely, with the crystal content ranging from about 1 to about 90 percent by weight and more usually, particularly when the composite is prepared in the form of beads, in the range of about 2 to about 80 weight percent of the composite.

The stability of the alkylation catalyst of the invention may be increased by steaming. U.S. Pat. Nos. 4,663,492; 4,594,146; 4,522,929; and 4,429,176, the entire disclosures of which are incorporated herein by reference, describe conditions for the steam stabilization of zeolite catalyst which can be utilized to steam-stabilize the catalyst for use herein. The steam stabilization conditions include contacting the catalyst with, e.g., 5-100% steam at a temperature of at least about 300° C. (e.g., 300° -650° C.) for at least one hour (e.g., 1-200 hours) at a pressure of 101-2,500 kPa. In a more particular embodiment, the catalyst can be made to undergo steaming with 75-100% steam at 315° -500° C. and atmospheric pressure for 2-25 hours. In accordance with the steam stabilization treatment described in the above-mentioned patents, the steaming of the catalyst can take place under conditions sufficient to initially increase the Alpha Value of the catalyst, the significance of which is discussed infra, and produce a steamed catalyst having a peak Alpha Value. If desired, steaming can be continued to subsequently reduce the Alpha Value from the peak Alpha Value to an Alpha Value which is substantially the same as the Alpha Value of the unsteamed catalyst.

The alkylation process of this invention may be conducted such that the organic reactants, i.e., the alkylatable phenolic compound and the alkylating agent, are brought into contact with the catalyst in a suitable reaction zone, such as for example a fixed bed of the catalyst, under effective alkylation conditions. Such conditions include a temperature of between about 50° C. and about 500° C., a pressure of from about 0.1 to about 100 atmospheres, a feed weight hourly space velocity (WHSV) of between about 0.1 an about 200 and an alkylatable phenolic compound to alkylating agent mole ratio of from about 0.1:1 to about 50:1. The WHSV is based upon the weight of the catalyst compositions employed, i.e., the total weight of active catalyst (and binder if present). Preferred reaction conditions include a temperature within the approximate range of from about 100° C. to about 400° C., a pressure of from about atmospheric to about 25 atmospheres a feed WHSV of from about 1 to about 50 and an alkylatable phenolic compound to alkylating agent mole ratio of from about 0.5:1 to about 5:1. The reactants can be in either the vapor phase or the liquid phase and can be neat, i.e., free from intentional admixture or dilution with other material, or they can be brought into contact with the zeolite with the aid of carrier gases or diluents such as, for example, hydrogen or nitrogen.

The alkylation process described herein may be carried out as a batch-type, semi-continuous or continuous operation utilizing a fixed or moving bed catalyst system. A preferred embodiment entails use of a catalyst zone wherein the hydrocarbon charge is passed concurrently or countercurrently through a moving bed of particle-form catalyst. The latter, after use, is conducted to a regeneration zone where coke is burned from the catalyst in an oxygen-containing atmosphere (such as air) at elevated temperature, after which the regenerated catalyst is recycled to the conversion zone for further contact with the organic reactants.

In order to more fully illustrate the alkylation process of this invention and the manner of practicing same, the following examples are presented. In the examples illustrative of the synthesis of zeolite, whenever sorption data are set forth for comparison of sorptive capacities for water, cyclohexane and/or n-hexane, they were Equilibrium Adsorption values determined as follows:

A weighed sample of the calcined adsorbent was contacted with the desired pure adsorbate vapor in an adsorption chamber, evacuated to less than 1 mm Hg and contacted with 12 Torr of water vapor or 40 Torr of n-hexane or 40 Torr of cyclohexane vapor, pressures less than the vapor-liquid equilibrium pressure of the respective adsorbate at 90° C. The pressure was kept constant (within about ±0.5 mm Hg) by addition of adsorbate vapor controlled by a manostat during the adsorption period, which did not exceed about 8 hours. As adsorbate was adsorbed by the crystalline material, the decrease in pressure caused the manostat to open a valve which admitted more adsorbate vapor to the chamber to restore the above control pressures. Sorption was complete when the pressure change was not sufficient to activate the manostat. The increase in weight was calculated as the adsorption capacity of the sample in g/100 g of calcined adsorbant. Zeolite MCM-22 always exhibits Equilibrium Adsorption values of greater than about 10 wt. % for water vapor, greater than about 4.5 wt. %, usually greater than about 7 wt. % for cyclohexane vapor and greater than about 10 wt. % for n-hexane vapor. These vapor sorption capacities are a notable distinguishing feature of zeolite MCM-22 and are preferred for the zeolite component of catalyst for use herein.

When Alpha Value is examined, it is noted that the Alpha Value is an approximate indication of the catalytic cracking activity of the catalyst compared to a standard catalyst and it gives the relative rate constant (rate of normal hexane conversion per volume of catalyst per unit time). It is based on the activity of the highly active silica-alumina cracking catalyst taken as an Alpha of 1 (Rate Constant=0.016 sec⁻¹). The Alpha Test is described in U.S. Pat. No. 3,354,078, in the Journal of Catalysis, Vol. 4, p. 527 (1965); Vol. 6, p. 278 (1966); and Vol. 61, p. 395 (1980), each incorporated herein by reference as to that description. The experimental conditions of the test used herein include a constant temperature of 538° C. and a variable flow rate as described in detail in the Journal of Catalysis, Vol. 61, p. 395.

EXAMPLE 1

One part of sodium aluminate (43.5% Al₂ O₃, 32.2% Na₂ O, 25.6% H₂ O) was dissolved in a solution containing 1 part of 50% NaOH solution and 103.13 parts H₂ O. To this was added 4.50 parts hexamethyleneimine. The resulting solution was added to 8.55 parts of Ultrasil, a precipitated, spray-dried silica (about 90% SiO₂).

The reaction mixture had the following composition, in mole ratios:

    SiO.sub.2 /Al.sub.2 O.sub.3 =30.0

    OH.sup.- /SiO.sub.2 =0.18

    H.sub.2 O/SiO.sub.2 =44.9

    Na/SiO.sub.2 =0.18

    R/SiO.sub.2 =0.35

where R is hexamethyleneimine.

The mixture was crystallized in a stainless steel reactor, with stirring, at 150° C. for 7 days. The crystalline product was filtered, washed with water and dried at 120° C. After a 20 hour calcination at 538° C., the X-ray diffraction pattern contained the major lines listed in Table E. The sorption capacities of the calcined material were measured to be:

    ______________________________________                                         H.sub.2 O            15.2 wt. %                                                Cyclohexane          14.6 wt. %                                                n-Hexane             16.7 wt. %                                                ______________________________________                                    

The surface area of the calcined crystalline material was measured to be 494 m² /g.

The chemical composition of the uncalcined material was determined to be as follows:

    ______________________________________                                         Component           wt. %                                                      ______________________________________                                         SiO.sub.2           66.9                                                       Al.sub.2 O.sub.3    5.40                                                       Na                  0.03                                                       N                   2.27                                                       Ash                 76.3                                                       SiO.sub.2 /Al.sub.2 O.sub.3, mole ratio =                                                          21.1                                                       ______________________________________                                    

                  TABLE E                                                          ______________________________________                                         Degrees        Interplanar                                                     2 Theta        d-Spacing (A)                                                                             I/I.sub.o                                            ______________________________________                                          2.80          31.55      25                                                    4.02          21.98      10                                                    7.10          12.45      96                                                    7.95          11.12      47                                                   10.00          8.85       51                                                   12.90          6.86       11                                                   14.34          6.18       42                                                   14.72          6.02       15                                                   15.90          5.57       20                                                   17.81          4.98        5                                                   20.20          4.40       20                                                   20.91          4.25        5                                                   21.59          4.12       20                                                   21.92          4.06       13                                                   22.67          3.92       30                                                   23.70          3.75       13                                                   24.97          3.57       15                                                   25.01          3.56       20                                                   26.00          3.43       100                                                  26.69          3.31       14                                                   27.75          3.21       15                                                   28.52          3.13       10                                                   29.01          3.08        5                                                   29.71          3.01        5                                                   31.61           2.830      5                                                   32.21           2.779      5                                                   33.35           2.687      5                                                   34.61           2.592      5                                                   ______________________________________                                    

EXAMPLE 2

A portion of the calcined crystalline product of Example 1 was tested in the Alpha Test and was found to have an Alpha Value of 224.

EXAMPLES 3-5

Three separate synthesis reaction mixtures were prepared with compositions indicated in Table F. The mixtures were prepared with sodium aluminate, sodium hydroxide, Ultrasil, hexamethyleneimine (R) and water. The mixtures were maintained at 150° C., 143° C. and 150° C., respectively, for 7, 8 and 6 days respectively in stainless steel autoclaves at autogenous pressure. Solids were separated from any unreacted components by filtration and then water washed, followed by drying at 120° C. The product crystals were subjected to X-ray diffraction, sorption, surface area and chemical analyses. The results of the sorption, surface area and chemical analyses are presented in Table F. The sorption and surface area measurements were of the calcined product.

                  TABLE F                                                          ______________________________________                                         Example          3         4       5                                           ______________________________________                                         Synthesis Mixture, mole ratios                                                 SiO.sub.2 /Al.sub.2 O.sub.3                                                                     30.0      30.0    30.0                                        OH.sup.- /SiO.sub.2                                                                             0.18      0.18    0.18                                        H.sub.2 O/SiO.sub.2                                                                             19.4      19.4    44.9                                        Na/SiO.sub.2     0.18      0.18    0.18                                        R/SiO.sub.2      0.35      0.35    0.35                                        Product Composition, Wt. %                                                     SiO.sub.2        64.3      68.5    74.5                                        Al.sub.2 O.sub.3 4.85      5.58    4.87                                        Na               0.08      0.05    0.01                                        N                2.40      2.33    2.12                                        Ash              77.1      77.3    78.2                                        SiO.sub.2 /Al.sub.2 O.sub.3, mole ratio                                                         22.5      20.9    26.0                                        Adsorption, Wt. %                                                              H.sub.2 O        14.9      13.6    14.6                                        Cyclohexane      12.5      12.2    13.6                                        n-Hexane         14.6      16.2    19.0                                        Surface Area, m.sup.2 /g                                                                        481       492     487                                         ______________________________________                                    

EXAMPLE 6

Quantities of the calcined (538° C. for 3 hours) crystalline silicate products of Examples 3, 4 and 5 were tested in the Alpha Test and found to have Alpha Values of 227, 180 and 187, respectively.

EXAMPLE 7

To demonstrate a further preparation of the present zeolite, 4.49 parts of hexamethyleneimine was added to a solution containing 1 part of sodium aluminate, 1 part of 50% NaOH solution and 44.19 parts of H₂ O. To the combined solution were added 8.54 parts of Ultrasil silica. The mixture was crystallized with agitation at 145° C. for 59 hours and the resultant product was water washed and dried at 120° C.

Product chemical composition, surface area and adsorption analyses results were as set forth in Table G:

                  TABLE G                                                          ______________________________________                                         Product Composition (uncalcined)                                               C                      12.1   wt. %                                            N                      1.98   wt. %                                            Na                     640    ppm                                              Al.sub.2 O.sub.3       5.0    wt. %                                            SiO.sub.2              74.9   wt. %                                            SiO.sub.2 /Al.sub.2 O.sub.3, mole ratio                                                               25.4                                                    Adsorption, wt. %                                                              Cyclohexane            9.1                                                     N-Hexane               14.9                                                    H.sub.2 O              16.8                                                    Surface Area, m.sup.2 /g                                                                              479                                                     ______________________________________                                    

EXAMPLE 8

Twenty-five grams of solid crystal product from Example 7 were calcined in a flowing nitrogen atmospheres at 538° C. for 5 hours, followed by purging with 5% oxygen gas (balance N₂) for another 16 hours at 538° C.

Individual 3 g samples of the calcined material were ion-exchanged with 100 ml of 0.1N TEABr, TPABr and LaCL₃ solution separately. Each exchange was carried out at ambient temperature for 24 hours and repeated three times. The exchanged samples were collected by filtration, water-washed to be halide-free and dried. The compositions of the exchanged samples are tabulated below demonstrating the exchange capacity of the present crystalline silicate for different ions.

    ______________________________________                                         Exchange Ions                                                                  Ionic Composition, wt. %                                                                        TEA       TPA     La                                          ______________________________________                                         Na                0.095     0.089   0.063                                      N                0.30      0.38    0.03                                        C                2.89      3.63    --                                          La               --        --      1.04                                        ______________________________________                                    

EXAMPLE 9

The La-exchanged sample from Example 8 was sized to 14 to 25 mesh and then calcined in air at 538° C. for 3 hours. The calcined material had an Alpha Value of 173.

EXAMPLE 10

The calcined sample La-exchanged material from Example 9 was severely steamed at 649° C. in 100% steam for 2 hours. The steamed sample had an Alpha Value of 22, demonstrating that the zeolite has very good stability under severe hydrothermal treatment.

EXAMPLE 11

This example illustrates the preparation of the present zeolite where X in the general formula, supra, is boron. Boric acid, 2.59 parts, was added to a solution containing 1 part of 45% KOH solution and 42.96 parts H₂ O. To this was added 8.56 parts of Ultrasil silica, and the mixture was thoroughly homogenized. A 3.88 parts quantity of hexamethyleneimine was added to the mixture.

The reaction mixture had the following composition in mole ratios:

    SiO.sub.2 /B.sub.2 O.sub.3 =6.1

    OH.sup.- /SiO.sub.2 =0.06

    H.sub.2 O/SiO.sub.2 =19.0

    K/SiO.sub.2 =0.06

    R/SiO.sub.2 =0.30

where R is hexamethyleneimine.

The mixture was crystallized in a stainless steel reactor, with agitation, at 150° C. for 8 days. The crystalline product was filtered, washed with water and dried at 120° C. A portion of the product was calcined for 6 hours at 540° C. and found to have the following sorption capacities:

    ______________________________________                                         H.sub.2 O (12 Torr)                                                                              11.7 wt. %                                                   Cyclohexane (40 Torr)                                                                             7.5 wt. %                                                   n-Hexane (40 Torr)                                                                               11.4 wt. %                                                   ______________________________________                                    

The surface area of the calcined crystalline material was measured (BET) to be 405m² /g.

The chemical composition of the uncalcined material was determined to be as follows:

    ______________________________________                                         N                       1.94   wt. %                                           Na                      175    ppm                                             K                       0.60   wt. %                                           Boron                   1.04   wt. %                                           Al.sub.2 O.sub.3        920    ppm                                             SiO.sub.2               75.9   wt. %                                           Ash                     74.11  wt. %                                           SiO.sub.2 /Al.sub.2 O.sub.3, molar ratio =                                                             1406                                                   SiO.sub.2 /(Al + B).sub.2 O.sub.3, molar ratio =                                                       25.8                                                   ______________________________________                                    

EXAMPLE 12

A portion of the calcined crystalline product of Example 11 was treated with NH₄ Cl and again calcined. The final crystalline product was tested in the Alpha Test and found to have an Alpha Value of 1.

EXAMPLE 13

This example illustrates another preparation of the zeolite in which X of the general formula, supra, is boron. Boric acid, 2.23 parts, was added to a solution of 1 part of 50% NaOH solution and 73.89 parts H₂ O. To this solution was added 15.29 parts of HiSil silica followed by 6.69 parts of hexamethyleneimine. The reaction mixture had the following composition in mole ratios:

    SiO.sub.2 /B.sub.2 O.sub.3 =12.3

    OH.sup.- /SiO.sub.2 =0.056

    H.sub.2 O/SiO.sub.2 =18.6

    K/SiO.sub.2 =0.056

    R/SiO.sub.2 =0.30

where R is hexamethyleneimine.

The mixture was crystallized in a stainless steel reactor, with agitation, at 300° C. for 9 days. The crystalline product was filtered, washed with water and dried at 120° C. The sorption capacities of the calcined material (6 hours at 540° C.) were measured:

    ______________________________________                                         H.sub.2 O (12 Torr)    14.4 wt. %                                              Cyclohexane (40 Torr)   4.6 wt. %                                              n-Hexane (40 Torr)     14.0 wt. %                                              ______________________________________                                    

The surface area of the calcined crystalline material was measured to be 438m² /g.

The chemical composition of the uncalcined material was determined to be as follows:

    ______________________________________                                         Component               Wt. %                                                  ______________________________________                                         N                       2.48                                                   Na                      0.06                                                   Boron                   0.83                                                   Al.sub.2 O.sub.3        0.50                                                   SiO.sub.2               73.4                                                   SiO.sub.2 /Al.sub.2 O.sub.3, molar ratio = 249                                 SiO.sub.2 /(Al + B).sub.2 O.sub.3, molar ratio = 28.2                          ______________________________________                                    

EXAMPLE 14

A portion of the calcined crystalline product of Example 13 was tested in the Alpha Test and found to have an Alpha Value of 5.

EXAMPLE 15

This example demonstrates the alkylation of phenol with alpha-C₁₄ olefin over catalyst comprising zeolite MCM-22 to provide a mixture of alkylated phenols.

The MCM-22 was prepared by adding 4.49 parts quantity of hexamethyleneimine to a mixture containing 1.00 part sodium aluminate, 1.00 part 50% NaOH, 8.54 parts Ultrasil VN3 and 44.19 parts deionized H₂ O. The reaction mixture was heated to 143° C. (290° F.) and stirred in an autoclave at that temperature for crystallization. After full crystallinity was achieved, the majority of the hexamethyleneimine was removed from the autoclave by controlled distillation and the zeolite crystals separated from the remaining liquid by filtration, washed with deionized H₂ O and dried.

A portion of the zeolite crystals was combined with Al₂ O₃ to form a mixture of 65 parts, by weight, zeolite and 35 parts Al₂ O₃. Water was added to this mixture to allow the resulting catalyst to be formed into extrudates. The catalyst was activated by calcining in nitrogen at 540° C. (1000° F.), followed by aqueous ammonium nitrate exchange and calcining in air at 540° C. (1000° F.).

Alkylation was carried out in a 1 liter autoclave using 400 grams (2.02 moles) olefin, 95 grams (1.01 moles) phenol and 38 grams catalyst. Reaction time was six hours at 350° F. under 400 psig nitrogen.

Analysis of the product indicated the presence of mono-, di- and tri-tetradecyl phenols. 

What is claimed is:
 1. A process for the production of a relatively long chain alkyl-substituted phenolic compounds which comprises contacting at least one alkylatable phenolic compound with at least one alkylating agent possessing an alkylating aliphatic group having at least six carbon atoms under alkylation reaction conditions and in the presence of an alkylation catalyst to provide an alkylated phenol possessing at least one alkyl group derived from said alkylating agent, said catalyst comprising a synthetic porous crystalline material characterized by an X-ray diffraction pattern including values substantially as set forth in Table A of the specification.
 2. The process of claim 1 wherein the synthetic porous crystalline material is characterized by X-ray diffraction pattern including values substantially as set forth in Table B of the specification.
 3. The process of claim 1 wherein the synthetic porous crystalline material is characterized by an X-ray diffraction pattern including values substantially as set forth in Table C of the specification.
 4. The process of claim 1 wherein the synthetic porous crystalline material is characterized by an X-ray diffraction pattern including values substantially as set forth in Table D of the specification.
 5. The process of claim 1 wherein the synthetic porous crystalline material has a composition comprising the molar relationship

    X.sub.2 O.sub.3 :(n)YO.sub.2,

wherein n is at least about 10, X is a trivalent element and Y is a tetravalent element.
 6. The process of claim 2 wherein the synthetic porous crystalline material has a composition comprising the molar relationship:

    X.sub.2 O.sub.3 :(n)YO.sub.2,

wherein n is at least about 10, X is a trivalent element and Y is a tetravalent element.
 7. The process of claim 3 wherein the synthetic porous crystalline material has a composition comprising the molar relationship

    X.sub.2 O.sub.3 :(n)YO.sub.2,

wherein n is at least 10, X is a trivalent element and Y is a tetravalent element.
 8. The process of claim 4 wherein the synthetic porous crystalline material has a composition comprising the molar relationship

    X.sub.2 O.sub.3 :(n)YO.sub.2,

wherein n is at least about 10, X is a trivalent element and Y is a tetravalent element.
 9. The process of claim 1 wherein the synthetic porous crystalline material possesses equilibrium adsorption capacities of greater than about 4.5 wt. % for cyclohexane vapor and greater than about 10 wt. % for n-hexane vapor.
 10. The process of claim 5 wherein X is selected from the group consisting of aluminum, boron, gallium and combinations thereof and Y is selected from the group consisting of silicon, germanium and combinations thereof.
 11. The process of claim 5 wherein X comprises aluminum and Y comprises silicon.
 12. The process of claim 1 wherein said synthetic porous crystalline material has been treated to replace original cations, at least in part, with a cation or mixture of cations selected from the group consisting of hydrogen, hydrogen precursors, rare earth metals, and metals of Groups IIA, IIA, IVA, IB, IIB, IIIB, IVB, VIB and VIII of the Periodic Table.
 13. The process of claim 1 wherein synthetic porous crystalline material has been thermally treated at a temperature up to about 925° C. in the presence or absence of steam.
 14. The process of claim 12 wherein said synthetic porous crystalline material has been thermally treated at a temperature up to about 925° C. in the presence or absence of steam.
 15. The process of claim 1 wherein the alkylating aliphatic group contains at least about 8 carbon atoms.
 16. The process of claim 1 wherein the alkylating aliphatic group contains at least about 12 carbon atoms.
 17. The process of claim 1 wherein the alkylating agent is an olefin.
 18. The process of claim 1 wherein the alkylating agent is an alcohol.
 19. The process of claim 1 wherein the alkylating agent is an alkyl halide.
 20. The process of claim 1 wherein the alkylatable phenolic compound is selected from the group consisting of phenol, cresols and xylenols.
 21. The process of claim 1 wherein the alkylatable phenolic compound is selected from the group consisting of naphthols, anthranols and phenanthranols.
 22. The process of claim 1 wherein the alkylation conditions include a temperature of from about 50° to about 500° C., a pressure of from about 0.1 to about 100 atmospheres, a WHSV of from about 0.1 to about 200 hr⁻¹ and an alkylatable phenolic compound to alkylating agent mole ratio of from about 0.1:1 to about 50:1.
 23. The process of claim 1 wherein the alkylation conditions include a temperature of from about 100° to about 400° C., a pressure of from about atmospheric to about 25 atmospheres a WHSV of from about 1 to about 50 hr⁻¹ and an alkylatable phenolic compound to alkylating agent mole ratio of from about 0.5:1 to about 5:1. 